Coated hard alloy tool

ABSTRACT

An improved coated hard alloy tool having a substrate made of a hard alloy, and a multi-layer ceramic coating film provided on the surface of the substrate, the coating film including at least one oxide layer. The top several layers of the coating film are missing partially or completely in an area where the tool is brought into frictional contact with a workpiece. At least one oxide layer (such as Al 2  O 3  layer) is included in the missing layers. This increases wear resistance of the coated hard alloy tool.

BACKGROUND OF THE INVENTION

The present invention relates to a coated hard alloy tools used as acutting tool that is required to show high wear resistance or otherwear-resistant tool, and more particularly to a tool formed from a hardalloy and coated with a multilayered ceramic film which has goodresistance to peeling and chipping.

Conventional steel cutting tools were made of cemented carbide (WC-Coalloy with carbonitrides of Ti, Ta or Nb added). However, in order tocope with increasing cutting speeds, most of such tools are nowadaysformed from a matrix of a cemented carbide, a cermet or a ceramicmaterial such as alumina or silicon nitride having its surface coated byCVD or PVD process with a 3-10 micron thick film of a carbide, nitride,carbonitride, carbooxide, boron nitride or oxide of a metal belonging tothe IVa, Va or VIa group in the periodic table or Al, or their solidsolution.

First-generation such coated tools had mainly a coating of a titaniumcompound of high hardness so that they showed high wear resistance attheir rake face. But as the cutting speed of the tools increases, inorder to reduce crator-like wear formed in the rake face, such a coatingwas gradually replaced by a triple-layer coating consisting of alowermost titanium compound layer, an intermediate oxidation-resistantAl₂ O₃ layer, and a top gold TiN layer which is used to distinguish usedcorners from not-used ones. Most of the present-day tools have a coatingof this type. In particular, it is now considered essential that such acoating include an oxide layer such as Al₂ O₃.

By increasing the thickness of the coating or by providing an Al₂ O₃layer in the coating, the wear resistance of the tools improved. Buttheir resistance to chipping decreased. This is presumably because thecoating itself is a brittle material and thus it is likely to suffercracks that extend the entire thickness of the coating. Another reasonis that by providing a layer of Al₂ O₃ in the coating, the surfaceroughness of the coating increases. Thus, in order to improve theresistance to chipping, Unexamined Japanese Patent Publication 55-150941and Examined Japanese Patent Publication 5-9201 proposed to reduce thethickness of the coating only at the ridge of the cutting edge. For thesame purpose, Unexamined Japanese Patent Publications 62-228305 and5-57507 proposed to limit the surface roughness of the Al₂ O₃ layerbelow a predetermined value.

The solutions proposed in these publications were effective to somedegree in improving the resistance to chipping, but could not improvethe wear resistance of the tool and particularly the peel resistance ofthe film coating. The tool can be damaged easily once their coatinglayer peels. Thus, the life of such a tool was short. A tool made of ahard alloy and having a coating which is less likely to peel has beenlong awaited.

It is an object of the present invention to provide a coated hard alloytool that exhibits high resistance to chipping, wear and peeling in abalanced manner, and thus reveals high performance in cutting metals,and that shows long life.

SUMMARY OF THE INVENTION

In order to achieve this object, we, the present inventors, studied themechanism in cutting materials. As a result, we found that it ispossible to dramatically improve the peel resistance and the resistanceto chipping in a balanced manner if such a tool comprises a substratemade of a hard alloy, and a multi-layer ceramic coating film provided onthe surface of the substrate, the coating film including at least oneoxide layer, the top several layers of the coating film being missingpartially or completely in an area where the tool is brought intofrictional contact with a workpiece, at least one oxide layer beingincluded in the missing layers, whereby a non-oxide layer is exposed atthe area where the top several layers are missing.

It is most desirable to completely remove the oxide layer or layers inthe frictional contact area such as the area along the ridge of thecutting edge. But the effect of the invention is expectable even if suchoxide layers are removed only partially, or even if at least one of aplurality of oxide layers is partially or completely removed along theentire ridge of the cutting edge.

The term "ridge of the cutting edge" herein used refers to a portion ofthe cutting edge which was subjected to strengthening treatment, e.g.the portion designated by the letter A in FIGS. 1B and 1C. In bothfigures, numeral 1 designates the rake face and 2 does the flank. Theridge of the cutting edge shown in FIG. 1B is strengthened by roundhoning. In FIG. 1C, it is strengthened by chamfering. Instead of flatchamfering as shown in FIG. 1C, the ridge may be strengthened byproviding a moderately curved chamfer.

To achieve the effect of the present invention, the length of theportion of the cutting edge where the oxide coating layer is removed hasto be not less than 10% of the effective cutting length of the cuttingedge. If this percentage is 50% or higher, better results will beachievable. Best results can be expected if it is 100%. This percentageis measured in the following manner: The nose portion of the tool isphotographed from a suitable direction with a scanning electronmicroscope (SEM) so that the existence of the oxide layer can bechecked; a line is drawn on the photo thus taken so as to run in theridge of the cutting edge in parallel to the cutting edge; the length ofthe oxide layer-free portions along the line is measured; and the ratioof this length to the length of the entire portion of the cutting edgeactually used in cutting operation and including the arcuate noseportion 3 (FIG. 1A) is given in percentage.

FIGS. 4A-4E show in detail how this percentage is measured. The toolused has a three-layer coating consisting of innermost TiCNlayer/intermediate Al₂ O₃ layer/outermost TiN layer. The portion of thecutting edge designated by α in FIG. 4A is the portion actually used incutting. FIGS. 4B and 4C show SEM-created images that cover the portionα of the cutting edge after partially removing the upper coating layers.FIGS. 4D and 4E are sections taken along line X-Y of FIGS. 4A and 4B,respectively. In these composition images, the TiN, Al₂ O₃ and TiCNlayers look in different color tones. Parallel lines C are drawn on theimages of FIGS. 4B and 4C in parallel to the cutting edge. The rate ofthe portion along these lines where Al₂ O₃ or TiCN is exposed ismeasured. In FIG. 4B, Al₂ O₃ layer is completely missing along the lineC. In other words, the rate of Al₂ O₃ -free portion is 100%. In FIG. 4C,there are a plurality of portions along the line C where Al₂ O₃ and TiCNare exposed. In this case, the removal rate of the oxide layer is givenby (a1+a2+. . . a8)/effective cutting length of the cutting edge, wherea1-a8 are the lengths of the portions along the line C where theinnermost TiCN layer is exposed.

If the coating contains a plurality of oxide layers, all of them do nothave to be removed. But any Al₂ O₃ layer or layer mainly composed of Al₂O₃ should be removed completely from the ridge of the cutting edge,because Al₂ O₃ is especially low in resistance to seizure. By the layermainly composed of Al₂ O₃, we mean composite layers of Al₂ O₃ and ZrO₂,Al₂ O₃ and AlN, or Al₂ O₃ and TiC in which Al₂ O₃ is a major component.

The underlying film layer which is exposed by removing the top severallayers in the coating should be one mainly composed of nitrides orcarbonitrides, preferably a TiCN film having a C to N mole ratio of 5:5to 7:3. More preferably, the underlying film which has been exposed byremoving the top layers should have a residual stress of -5 to 10kgf/mm². Also, such an exposed inner layer should preferably have anaverage surface roughness Ra of 0.05 μm or less.

When cutting a metal, especially a steel, the maximum temperature at therake face can reach as high as 1000° C. or more. It is thereforenecessary to coat such a tool with an oxide which is highly resistant tooxidation. Thus, commercially available tools are coated with an oxidefilm, typically an Al₂ O₃ film. We conducted detailed observation ofthese tools to check how they are damaged. As a result, we discoveredthat many of them were discarded in spite of the fact that wear was veryslight. We further observed the cutting edges of such discarded insertsunder a scanning electron microscope. In this observation, many minutechippings were found along the ridge of the cutting edge. At thesechipped portions, the matrix of a cemented carbide was exposed. If suchinserts were still kept in use for cutting, welding might occur at theportions where the matrix is exposed, or wear or chipping might progressrapidly. Thus, such inserts could cause serious trouble in productionline. This will be the reason why these inserts are discarded as uselesseven though they are worn little.

We therefore thought that if such minute chippings were reduced, itcould be possible to extend the life of such inserts. We thus examinedthe coating film in an attempt to find out in what mechanism it isdamaged. As a result, we found out that the temperature at the ridge ofthe cutting edge during cutting is lower than the temperature at therake face, so that adhesive wear tends to occur, and frictional stressproduced at the rake face becomes maximum at the ridge of the cuttingedge; chips thus adhere first to the ridge of the cutting edge; and thecoating film is peeled off by the frictional stress, so that minutechippings occur in the coating film. Thus, we thought that if thecoating film has such a structure or is formed from such a material thatchips are less likely to adhere to the ridge of the cutting edge, itcould be possible to reduce minute chippings or peelings of the coatingfilm observed on conventional discarded inserts.

Then, the present inventors have tried to find the best way to reduceadhesive wear of the coating film and found the solution as disclosed inthe present application. Namely, the occurrence of adhesion is relatedto physical surface irregularities as represented by surface roughness.In Unexamined Japanese Patent Publications 62-228305 and 5-57507, trialswere made to improve the surface roughness of the Al₂ O₃ layer bypost-treatment to prevent the peeling, decrease in strength and adhesionof the coating film.

But adhesion and welding are related not only to the surface roughnessbut to chemical phenomena such as seizure. Thus, we compared theresistance to seizure of oxide ceramics with those of nitrides andcarbides. The results for the oxides were the worst of all. Heretofore,trials were made to reduce the friction coefficient by improving thesurface roughness of oxides such as Al₂ O₃. But because the resistanceto seizure of such oxides is low, their peel resistance is still verylow. We therefore tried to partially or completely remove oxide layerssuch as Al₂ O₃ from the ridge of the cutting edge, where the frictionalstress becomes maximum. We confirmed that with this arrangement, thecoating layer was least likely to seize to the workpiece and its peelresistance improved dramatically to such an extent that no chippingswere observed and that it was possible to dramatically extend the lifeof the tool.

Since nitrides and carbides are less likely to seize to metals, the peelresistance is improved if such a layer is exposed at the ridge of thecutting edge. Preferably, such a layer should be formed from a TiCN filmso that the mol fraction C:N will be between 5:5 and 7:3, because such afilm has not only excellent resistance to seizure but it also showsexceptionally high wear resistance. Thus, the tool having such a layerexposed will show a markedly long service life. A TiCN film having sucha composition can be formed by an ordinary HT (HIGH TEMPERATURE)-CVD.But to control the C-to-N ratio more stably, such a film should beformed by a CVD method that uses an organic CN compound as a reactiongas.

The mole ratio of C to N can be calculated by measuring the latticeconstant of the TiCN film by ESCA (ELECTRON SPECTROSCOPY FOR CHEMICALANALYSIS), EPMA (ELECTRON PROBE-MICRO ANALYZER), or by X-ray analysis.The results of X-ray analysis conducted by us revealed that where themole ratio of C to N was within the range between 5:5 and 7:3, thelattice constant of the TiCN film was 4.275 to 4.295Å. Within thisrange, the resistances to seizure and wear were excellent. Consideringthe stoichiometry of TiCN, this result may sound a little contradictory.This contradiction presumably results from the fact that the TiCN filmhas such a nonstoichiometric composition as represented by Ti(CN)0.9,instead of strictly stoichiometric composition.

By adjusting the residual stress in the film exposed by removing theupper layers to -5 to 10 kgf/mm², we found that the peel resistanceimproved still further. If the residual stress is less than -5 kgf/mm²,the film may be destroyed under compressive force. If more than 10kgf/mm², the peel resistance will improve little. Thus such residualstress should be within the range of -5 to 10 kgf/mm².

We also found the fact that if the average of the surface roughness Raof the film exposed at the portion where the top layers are removed is0.05 μm or less, part of the oxide layer remains along the ridge of thecutting edge, so that the peel resistance of the film improves stillfurther even if Rmax is large. If larger than 0.05 μm, the peelresistance will not improve sufficiently.

The flank face of the insert is not heated to so high a temperatureduring cutting as at the rake face. Thus, an oxide film on the flankwould serve little to improve the wear resistance. Rather, such an oxidefilm tends to abrade the flank face by peeling off in lumps, thuslowering the wear resistance. For higher wear resistance, the toplayer-free portion on the flank should be wider than that on the rakeface. On the other hand, if it is desired to improve the resistance tochipping, the top layer-free portion on the flank should be wider thanthat on the rake face, or otherwise the top layer-free portion at thearcuate nose portion should be wider than that on the straight portionof the cutting edge. Thus, the widths of the top layer-free portionsshould be determined depending upon which of the abovementionedproperties of the tool is of the most importance.

In the present invention, after forming a coating layer on a hard alloyby CVD or PVD, the thickness of the coating is reduced along the ridgeof the cutting edge by barrel polishing, shot blasting, shot peening, byfinishing with an elastic grindstone, a resin brush having abrasivegrains, or a roller, by burnishing, chemical treating, ultrasonicvibration, or laser treating.

Whether or not there exists an oxide layer on the ridge of the cuttingedge can be confirmed by WDS (WAVELENGTH DISPERSIVE SPECTROSCOPY) usingan A-SEM (ANALYTICAL SCANNING MICROSCOPE), by EDS (ENERGY DISPERSIVESPECTROSCOPY) analysis, or by observing a given section under an opticalmicroscope, an SEM or an EPMA after polish-lapping and etching.

The residual stress in the film can be measured by the sin2φ methodusing X-rays. If there remains an oxide film layer as in FIG. 4C, it isdifficult to measure the average of surface roughness values Ra of thefilm with a contact-type surface roughness meter. Thus, we measured itunder an SEM for rough surface observation using electron. beams. Theaverage of the surface roughness values Ra refers to the values Rameasured along 180 lines that extend in the horizontal direction in avisual field.

In the state shown in FIG. 4C, the roughness of the surface includingthe surface of Al₂ O₃ is extremely high. Namely, the Rmax of surfaceroughness values exceeds the thickness of the removed oxide layer. Inthe present invention, the surface roughness of the coating layer notincluding such an oxide layer is set below a predetermined level. Wehave found that with this arrangement, it is possible to maximize thepeel resistance of the coating.

The coated hard alloy according to the present invention is less likelyto weld and thus to suffer peeling of its coating film or chipping ofits cutting edge. Its life is therefore long and the workpieces cut bysuch a tool will present a smoother surface.

Other features and objects of the present invention will become apparentfrom the following description made with reference to the accompanyingdrawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a partial perspective view of a cutting tool (insert).

FIG. 1B is an enlarged sectional view taken along line X-Y of FIG. 1A;

FIG. 1C is a view similar to FIG. 1B but showing a different cuttingedge;

FIG. 2 is an enlarged sectional view of a cutting edge of an insertembodying the present invention;

FIG. 3 is a sectional view of a workpiece used in a cutting test; and

FIGS. 4A to 4E are views showing how the removal rate of oxide layers ismeasured.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Now description is made of Examples of the present invention.

Experiment 1

We prepared sample Nos. 1-11 of coated hard alloy tool (insert) (Table3). They were formed by combining different kinds of hard alloys a-fshown in Table 1 and having the shape of type CNMG433 with differentkinds of hard films or coatings A-H shown in Table 2 formed by HT (HIGHTEMPERATURE)-CVD. The coating of layer of Sample No. 1 was removed alongthe ridge of the cutting edge by use of a vibratory barreling machine.By changing the treating time, we prepared Control Article 1 andArticles 1-6 of the invention which have different removal rates ofoxide layers along the ridge of the cutting edge as shown in Table 4.

The results of observation under an A-SEM confirmed that TiCN wasexposed at the portion where Al₂ O₃ has been removed. FIG. 1 shows asection of the cutting edge of a tool according to the invention, inwhich numeral 5 designates the substrate, and 4 does a multi-layerceramic coating film.

The removal rate of oxide layers along the ridge of the cutting edge wasmeasured by observing under an A-SEM. The tools of Control Article 1 andArticles 1-6 of the invention were used to cut a workpiece made ofSCM415 and having the shape as shown in FIG. 3 (a round rod having fourgrooves in the outer periphery so that cutting will be discontinuous).We compared them for service lives.

Cutting conditions

Cutting speed: 200 m/min

Feed: 0.3 mm/rev

Depth of cut: 1.5 mm

Type of cutting: Wet type

Holder used: PCLNR2525-43

We observed a reflected electronic image of each tool picked up by anSEM and determined that its life had expired when its substrate wasexposed.

In this test, as shown in FIG. 4, Articles 1-6 of the invention allexhibited higher peel resistance than Control Article 1, in which theoxide layer was not removed at all. Article 4-6, in which oxide layerswere removed by more than 50%, showed particularly good results. Mostnotably, Article 6, in which oxide layers were removed 100% along theridge of the cutting edge, showed six times as high a peel resistance asthat of Control Article 1.

Experiment 2

We prepared Articles 6 and 7 of the invention by removing oxide layersby 100% from tool samples Nos. 1 and 6 along the ridge of the cuttingedge with a diamond brush so that they will have the same structure andthickness of coating at the ridge of the cutting edge and the sameprocessing amount at the tip of the cutting edge. They were subjected tothe same cutting test as in Experiment 1. As is apparent from the testresults shown in Table 5, both Articles showed similar performance inthe peel resistance. As for Control Articles 1 and 2 which correspond toArticles 6 and 7 but have coatings not removed at all, the former wasinferior to the latter in peel resistance. When comparing Article 6, inwhich Al₂ O₃ was removed, with Article 7, in which ZrO₂ was removed, theformer showed higher improvement in peel resistance than the latter.This shows that in order to improve the peel resistance, Al₂ O₃ shouldbe removed rather than ZrO₂.

Experiment 3

We prepared Articles 8 and 9 according to the invention by removing Al₂O₃ and both Al₂ O₃ and ZrO₂, respectively, from sample No. 5 along theridge of the cutting edge by shot blasting using glass beads. They weresubjected to the same cutting test as in Experiment 1. As is apparentfrom the test results shown in Table 6, Article 9, in which all theoxide layers were removed along the ridge of the cutting edge, showedhigher performance than Article 8, in which only Al₂ O₃ was removed withZrO₂ remaining along the ridge of the cutting edge.

When comparing Article 6 with Article 9, the former, in which only alayer composed mainly of nitrides or carbonitrides remained along theridge of the cutting edge, was superior in peel resistance to thelatter, in which only a layer mainly composed of carbides remained alongthe ridge of the cutting edge.

Experiment 4

We prepared Articles 10-14 according to the invention by pressing anelastic grindstone against Sample Nos. 2-4, 7 and 8, respectively, fromabove their rake face to remove all the oxide layers along the ridges oftheir cutting edges. The inserts thus obtained were used to cut a moldmade of SKD62 under the following conditions:

Cutting conditions

Cutting speed: 100 m/min

Feed rate: 0.2 mm/rev

Depth of cut: 2 mm

Type of cutting and the holder used: the same as in Experiment 1.

The time taken until the substrate was exposed was used as the servicelife of each insert.

The test results are shown in Table 7. In spite of the fact that inArticles 10 and 11 according to the invention, oxide layers were missingalong the ridges of their cutting edges, Article 11 showed higher peelresistance. This is presumably because Article 11 kept only acarbonitride layer along the ridge of the cutting edge, while Article 10retained all of the carbide, nitride. and carbonitride layers. FromTable 7, it is also apparent that Article according to the inventionhaving a substrate made of ISO K20 cemented carbide or cermet and havingits oxide layers removed was higher in peel resistance than ControlArticles having a substrate also made of the same substrate but havingits oxide layers not removed at all.

Experiment 5

We prepared Articles 15-17 according to the invention by removing allthe oxide layers along the ridges of the cutting edges of Sample Nos.9-11, respectively, by use of a centrifugal barrel. The inserts preparedwere used to cut ductile cast iron FCD30 under the following conditions:

Cutting conditions

Cutting speed: 300 m/min

Feed rate: 0.4 mm/rev

Depth of cut: 2 mm

Type of cutting: Dry type

The holder used and the way of determining the service life were thesame as in other experiments.

The test results are shown in Table 8. From this table, it is apparentthat Articles according to the invention whose substrates were made ofdifferent kinds of ceramics all showed higher peel resistance thanControl Articles having the same substrates but having their oxidelayers not removed at all.

Experiment 6

We prepared Sample No. 12 having the same substrate and the same coatingstructure as Sample No. 1 except that the TiCN layer was formed by CVDusing an organic CN compound as a reaction gas. We compared the C:N molfraction in the TiCN layers on Sample Nos. 1 and 12 by ESCA. In SampleNo. 1, the C:N ratio was 8:2, while that of Sample No. 12 was 6:4. Weprepared Articles 18-20 from Sample No. 12 by removing Al₂ O₃ along theridges of the cutting edges at different rates in the same manner as inExperiment 1. They were subjected to the same cutting test as inExperiment 1. After removing Al₂ O₃, we observed the ridge of thecutting edge of each article under an A-SEM. It was confirmed that TiC-Nwas exposed locally or completely along the ridge of the cutting edge.The results of the test and the SEM observation are shown in Table 9. Wecompared Articles 1-6 and 18-20 according to the invention and ControlArticle 4, which was nothing but Sample No. 12 with its oxide layers notremoved at all. The inserts having a TiCN layer whose mole ratio of C:Nis between 5:5 and 7:3 and which is exposed partially or completelyalong the ridge of the cutting edge were especially high in peelresistance.

Experiment 7

Sample No. 1 (Control Article 1) and Articles 1-6 according to theinvention were used to cut a round rod made of SCM435 and having fourgrooves as shown in FIG. 3 under the following conditions:

Cutting conditions

Cutting speed: 100 m/min

Feed rate: 0.4 mm/rev

Depth of cut: 2 mm

Type of cutting: Dry type

The holder used was the same as in other experiments.

The life of each of the four corners of each insert was judged to haveexpired when it chipped. The average lifetime of the four corners wasused as the life of the entire insert.

The test results are shown in Table 10. From this table, it is apparentthat Articles according to the invention are all higher in theresistance to chipping than Comparative Article.

Experiment 8

We prepared Article 21 according to the invention by removing Al₂ O₃layer along the ridge of the cutting edge of Sample No. 13 using avibratory barreling machine. It was subjected to the same cutting testas in Experiment 1. The test results are shown in Table 11. As isapparent from this table, Article 21 was higher in peel resistance thanControl Article 5, even though only its outer Al₂ O₃ layer was removed.

Experiment 9

We prepared Articles 22-25 according to the invention by removing oxidesby 100% along the ridge of the cutting edge of Sample No. 2 by blasting(Article 22), by centrifugal barreling (Article 23), by vibratorybarreling (Article 24), and by rotary barreling (Article 25). Theresidual stress in the coating film along the ridge of the cutting edgeof each insert was measured by the sin2φ method using X-rays (Cr-Kα) onthe TiC (422) surface. The results of measurements are shown in Table12. These specimens were subjected to the same cutting test as inExperiment 1. The test results are also shown in Table 12. Articles 23and 24, which showed residual stresses within the range of -5 to 10kgf/mm², showed higher performance than Articles 22 and 25, whoseresidual stresses were outside the above range.

Experiment 10

We prepared Article 26 according to the invention by removing Al₂ O₃ by50% along the ridge of the cutting edge of Sample No. 1 prepared inExperiment 1 by blasting with iron balls having a diameter of about 200μm. We also prepared from Sample No. 1 Articles 27-29 according to theinvention by polishing with a burnishing compound using a rotary barrelfor different periods of time. We measured the average surface roughnessRa of the TiCN layer exposed along the ridge of the cutting edge with asurface roughness meter ERA4000 made by ELIONIX INC. at the 5000×magnification, the size of the visual field being 18×24 μm. The resultsof measurements are shown in Table 13. These specimens were subjected tothe same cutting test as in Experiment 1. The test results are alsoshown in Table 13. Articles 27, 28 according to the invention, which hadan average surface roughness Ra not exceeding 0.05 μm, showed higherperformance than Article 26, which had an average surface roughness Raof more than 0.05 μm.

The present invention is not limited to the examples described above.

For example, the concept of the invention is equally applicable tomilling cutters, rotary cutting tools such as drills and end mills, andother hard wearing tools used for non-cutting purposes such as punches,dies and slitters. Namely, it is because punches and slitters have edgessimilar to the ridge of the cutting edge of cutting tool, while dies,though having no such edges, have a surface adapted to be brought intofrictional contact with a workpiece. Thus, by removing oxide layerswhich are low in weld resistance from such edges and frictionalsurfaces, it would be possible to improve various properties of thesetools.

                  TABLE 1    ______________________________________    No.  Substrate    ______________________________________    a    ISO M20 cemented carbide    b    ISO K20 cemented carbide    c    commercially available cermet tool    d    commercially available silicon nitride tool    e    commercially available whisker-reinforced ceramic tool    f    commercially available Al.sub.2 O.sub.3 tool    ______________________________________

                  TABLE 2    ______________________________________    No.  Film layer    ______________________________________    A    Substrate/0.5 μm TiN/5 μm TiCN/2 μm Al.sub.2 O.sub.3/0.5         μm TiN    B    Subtrate/2 μm TiC/1 μm TiCN/3 μm TiN/1 μm         TiC/1 μm TiCO/2 μm Al.sub.2 O.sub.3    C    Substrate/7 μm TiCN/1 μm HfO.sub.2 /2 μm Al.sub.2 O.sub.3    D    Substrate/3 μm TiN/1 μm Al.sub.2 O.sub.3 /0.5 μm TiN    E    Substrate/15 μm TiC/10 μm Al.sub.2 O.sub.3    F    Substrate/5.5 μm TiC/1 μm ZrO.sub.2 /0.5 μm         TiBN/1 μm Al.sub.2 O.sub.3    G    Substrate/0.5 μm TiN/5 μm TiCN/2 μm ZrO.sub.2 /0.5 μm         TiN    H    Substrate/1 μm TiN/2 μm TiCN/15 μm Al.sub.2 O.sub.3 /15         μm         TiCN/2 μm Al.sub.2 O.sub.3 /0.5 μm TiN    ______________________________________

                  TABLE 3    ______________________________________    Sample No.    1        2     3     4   5   6   7   8   9   10  11  12                                 13    ______________________________________    Substrate           a     a     a   a   a   a   b   c   d   e   f                               a   a                               Film                                   A B C E F G B D D D D A H    ______________________________________

                  TABLE 4    ______________________________________    Sample No.      Removal ratio*                                Cutting time**    before processing                    (%)         (second)    ______________________________________    Control           1             0           40    article 1    Article 1           1            10           50    Article 2           1            23           80    Article 3           1            39          100    Article 4           1            54          150    Article 5           1            76          180    Article 6           1            100         240    ______________________________________     *Percentage in which the oxide was removed.     **Cutting time is the time elapsed for cutting before the substrate is     exposed.

                  TABLE 5    ______________________________________    Sample No.       Removal ratio                                 Cutting time    before processing                     (%)         (second)    ______________________________________    Control           1              0           40    article 1    Article 6           1             100         240    Control           6              0           70    article 2    Article 7           6             100         240    ______________________________________

                  TABLE 6    ______________________________________    Sample No.      Cutting time                               How much the    before processing                    (second)   oxide was removed*    ______________________________________    Control           5             30        Not processed    article 3    Article 8           5            100        Al.sub.2 O.sub.3 was                                   removed 100%    Article 9           5            170        Both Al.sub.2 O.sub.3 and                                   ZrO.sub.2 were removed                                   100%    ______________________________________     *How much the oxide was removed along the ridge of the cutting edge.

                  TABLE 7    ______________________________________                     Cutting  Ratio in    Sample No.       time     performance to    before processing                     (second) unprocessed articles    ______________________________________    Article 10            2            300      4.5    times    Article 11            3            420      7      times    Article 12            4            180      9      times    Article 13            7            240      4      times    Article 14            8            180      3      times    ______________________________________

                  TABLE 8    ______________________________________                     Cutting  Ratio in    Sample No.       time     performance to    before processing                     (second) unprocessed articles    ______________________________________    Article 15             9           320      6.4    times    Article 16            10           240      6      times    Article 17            11           220      5.5    times    ______________________________________

                  TABLE 9    ______________________________________    Sample No.       Removal ratio                                 Cutting time    before processing                     (%)         (second)    ______________________________________    Control  1            0           40    article 1    Article 6             1           100         240    Control 12            0           40    article 4    Article 18            12            31         130    Article 19            12            75         230    Article 20            12           100         340    ______________________________________

                  TABLE 10    ______________________________________                Sample No. Cutting time                before processing                           (second)    ______________________________________    Control Article 1                  1             2    Article 1     1            13    Article 2     1            24    Article 3     1            31    Article 4     1            67    Article 5     1            82    Article 6     1            93    ______________________________________

                  TABLE 11    ______________________________________    Sample No.       Removal ratio                                 Cutting time    before processing                     (%)         (second)    ______________________________________    Control 13            0           29    article 5    Article 21            13           100         328    ______________________________________     Control Article 5 is an unprocessed article of sample No. 13.

                  TABLE 12    ______________________________________    Sample No.       Residual stress                                 Cutting time    before processing                     (kgf/mm.sup.2)                                 (second)    ______________________________________    Control 2            30           30    article 6    Article 22            2            -7          140    Article 23            2             0          270    Article 24            2             8          230    Article 25            2            15          170    ______________________________________     Control Article 6 is an unprocessed article of sample No. 2.

                  TABLE 13    ______________________________________    Sample No.    Removal   Average     Cutting    before        ratio of  surface     time    processing    Al.sub.2 O.sub.3 (%)                            roughness (μm)                                        (second)    ______________________________________    Control 1          0        0.063      40    article 1    Article 26            1         50        0.055     130    Article 27            1         55        0.046     190    Article 28            1         60        0.039     230    Article 29            1         100       0.031     300    ______________________________________

What is claimed is:
 1. A coated hard alloy tool having a cutting edgeincluding a ridge and comprising a substrate made of a hard alloy, and amulti-layer ceramic coating film provided on the surface of saidsubstrate, said coating film including at least one oxide layer and atleast one non-oxide layer, the top several layers of said coating filmbeing missing partially or completely along said ridge, at least oneoxide layer being included in missing layers among said top severallayers, whereby a non-oxide layer, having an average surface roughnessRa not more than 0.05 μm, of said coating film is exposed along saidridge where said top several layers are missing.
 2. A coated hard alloytool having a cutting edge including a ridge and comprising a substratemade of a hard alloy, and a multi-layer ceramic coating film provided onthe surface of said substrate, said coating film including at least oneoxide layer and at least one non-oxide layer, the top several layers ofsaid coating film being missing partially or completely along saidridge, at least one oxide layer being included in missing layers amongsaid top several layers, whereby a non-oxide layer, having an averagesurface roughness Ra not more than 0.05 μm, of said coating film isexposed along said ridge where said top several layers are missing,wherein said at least one oxide layer included in said top severallayers is an Al₂ O₃ layer or a layer whose main component is Al₂ O₃. 3.A coated hard alloy tool having a cutting edge including a ridge andcomprising a substrate made of a hard alloy, and a multi-layer ceramiccoating film provided on the surface of said substrate, said coatingfilm including at least one oxide layer and at least one non-oxidelayer, the top several layers of said coating film being missingpartially or completely along said ridge, at least one oxide layer beingincluded in missing layers among said top several layers, whereby anon-oxide layer, having an average surface roughness Ra not more than0.05 μm, of said coating film is exposed along said ridge where said topseveral layers are missing, wherein said at least one oxide layerincluded in said top several layers is an Al₂ O₃ layer or a layer whosemain component is Al₂ O₃, and said layer exposed along said ridge wheresaid top several layers are missing is a layer whose main component is anitride or a carbonitride.
 4. A coated hard alloy tool having a cuttingedge including a ridge and comprising a substrate made of a hard alloy,and a multi-layer ceramic coating film provided on the surface of saidsubstrate, said coating film including at least one oxide layer and atleast one non-oxide layer, the top several layers of said coating filmbeing missing partially or completely along said ridge, at least oneoxide layer being included in missing layers among said top severallayers, whereby a non-oxide layer, having an average surface roughnessRa not more than 0.05 μm, of said coating film is exposed along saidridge where said top several layers are missing, wherein said at leastone oxide layer included in said top several layers is an Al₂ O₃ layeror a layer whose main component is Al₂ O₃, and said layer exposed alongsaid ridge where said top several layers are missing is a layer of TiCNhaving a mol fraction of C:N of between 5:5 and 7:3.
 5. A coated hardalloy tool having a cutting edge including a ridge and comprising asubstrate made of a hard alloy, and a multi-layer ceramic coating filmprovided on the surface of said substrate, said coating film includingat least one oxide layer and at least one non-oxide layer, the topseveral layers of said coating film being missing partially orcompletely along said ridge, at least one oxide layer being included inmissing layers among said top several layers, whereby a non-oxide layer,having an average surface roughness Ra not more than 0.05 μm, of saidcoating film is exposed along said ridge where said top several layersare missing, wherein said at least one oxide layer included in said topseveral layers is an Al₂ O₃ layer or a layer whose main component is Al₂O₃, and said layer exposed along said ridge where said top severallayers are missing is a layer whose main component is a nitride or acarbonitride, and has a residual stress of -5 to 10 kgf/mm².
 6. A coatedhard alloy tool having a cutting edge including a ridge and comprising asubstrate made of a hard alloy, and a multi-layer ceramic coating filmprovided on the surface of said substrate, said coating film includingat least one oxide layer and at least one non-oxide layer, the topseveral layers of said coating film being missing partially orcompletely along said ridge, all of oxide layers included in saidcoating film being removed along said ridge, whereby a non-oxide layer,having an average surface roughness Ra not more than 0.05 μm, of saidcoating film is exposed along said ridge where said top several layersare missing, wherein said at least one oxide layer included in said topseveral layers is an Al₂ O₃ layer or a layer whose main component is Al₂O₃, and said layer exposed along said ridge where said top severallayers are missing is a layer whose main component is a nitride or acarbonitride, and has a residual stress of -5 to 10 kgf/mm².
 7. A coatedhard alloy tool as claimed in claim 5 or 6, wherein said layer exposedalong said ridge where said top several layers are missing is a layer ofTiCN having a mol fraction of C:N of between 5:5 and 7:3.